Bms is coming - update

So, I sent out the BMS a few weeks ago.
It's been fixed, apparently the screen was the problem.
Will be here in a few weeks.
Then bike can get finished.

Haven't really got much time though; work, another website, gamma electrix and just other stuff.
So Ev's are on the sideline at the moment. But it is summer holiday after all.

Check out the RFID Kits and pre-built units: http://www.gammaelectrix.com/index.php?main_page=index&cPath=11_14
They are **on order** by the way.

Progress Update

Wow it's been a while now.
So so busy with school, now have holidays so lots of building to do.
Here are some pics I took a while ago.







I've also been busy with an electric bike I made with 72v of SLA 7ah. Just for fun really, never had an ebike. It uses a 9c front hubmotor using Lyen's 12FET controller which is awesome. Looking to make a a switchable LIPO pack for this ebike and a custom scooter I am currently building with a 1000w left over motor and a basic brushed setup.

A video here of the motorbike, from testing with the new batteries:



Oh and there has been no further progress on the bike since my last post as the BMS crapped out at the worst possible time, right when I was busy with other things aswell as right before I could do loads on the bike. Anyways, sending it off this week and should be fixed in a few weeks so the bike can be finished. I will be making a thread for the scooter as the build progressed.

And also... GammaElectrix now had Livechat available for anyone who needs questions to do with our products. We are also currently working on a forum based for NZ ev'ers and general projects to do with 2 wheeled electric vehicles.
http://www.gammaelectrix.com

Jake.

The Mounting Begins!

The Mounting Begins

Since I finally reached the milestone and painted the frame and all I could start mounting everything.

Started off by mounting the swingarm and shocks.



I then moved onto the front end and mounted all the painted parts. I also added the mirrors, kill switch, light, horn and indicator switches and the brakes and the throttle.





The awesome electronic speedo and cycle analyst.



I need to fabricate another mount for the rear brake mount because it was a sh**ty.
I put it all together and it looks pretty awesome.







I'm going to be ordering some new steering bearings and a road tyre and tube, maybe a new front rim.

Next things to do is mount all of this gear:



There is; an onboard charger, bms system, all the cabling, connectors, 12v system, dc/dc converter, rfid ignition module, alarm system, controller, contactor, fuse, lights etc and thats about it. Plus making some more mounts for the batteries, to make sure they are firm and dont fall out.




Jake

Battery mounts and Paint.

Battery mounts and Paint

I welded the battery mounts and welded them to the frame. Pretty good I say. Well, OK.




I welded the mount for the two bottom ones first, then the two single top ones.



Made sure they were square.



Just making sure they fit! :P





I then painted the whole frame with a rust converter primer, then with proper sandable primer.





Then I spray painted it Black, 2 layers of black.




PS. If your wondering about the steel. It is Galvanised, that's why it has a funny texture and is a bit thicker. That was the best I could find. Most suitable. Anyway I think it's turned out good.


Jake

Batteries arrived.

Batteries Arrived

About a month ago now, they arrived, they finally arrived. With a S*** load of money I had to pay to customs. YEY for sure :(

Well packaged. Been opened by customs though.


Anyways they are really nice, all very balanced and of very good quality.
The batteries are great, no scratches or damage at all.

attaching the BMS modules, daisy chain.


Balancing and testing all the settings.

BMS is VERY good, very simple yet very complex. Includes individual cell voltages etc on a screen. It also has alarms available and is connected to the charger, so nothing can be over charged etc. BMS also controls charger output depending on cell voltages. Balances it very well and evenly too.



What you get; bms stuff.

Another few updates coming.

RFID Keyless Ignition

This is the keyless ignition I made for the Electric motorbike. It uses a PICAXE 08M programmed to read the cards ID number and then decide whether this is a correct card or not.

If the correct card or tag is swiped over the reader (ID-12) the 08m sends a signal to the green LED showing that the bike is turned on. If a card that is not programmed into the 08m is swiped, the red LED flashes for 2 seconds, thus telling us that that card will not turn the bike on.

Thanks to the Bright Sparks!!!!

Code is available at: http://www.codeupload.com/755
SAEV Blog: http://tinyurl.com/28j9hev
Suzuki GT50 Conversion: http://tinyurl.com/2fqboqs

Any questions just ask.

Update

Been pretty busy lately and haven't been up to much with the bike.

A week ago I stripped it all down to the frame. I am wire brushing the sh** out of it. It's incredibly full of rust, luckily its surface rust only. Then I will be spraying it etc.

I am working on a small RFID system (PICAXE and ID-12) instead of the keyed ignition. So it will be KeyLess Ignition. Just swipe the tag/card and it'll turn on by the flip of the switch. It'll be a unique bike for sure.

I am working on a new site. I have a new website for the blog, well it redirects to the blog; http://blog.gammaelectrix.com The actual website is an online shop I'm working on. You can view it at http://www.gammaelectrix.com (may be under maintenance) It's being worked on and wont be online for sales in a while still.

Also, I've gotta get on to designing or thinking of what I'm gonna do with the fairings and tank etc. Little dash board or something....

Jake

New Page

Hello!!!!!

Just like to let you readers know that there now is a comments page. On this page you can post what you think of the site and my projects and all the questions you may have.

http://saundersev.blogspot.com/p/comments.html

Jake

Lead-acid Battery Sag---Log

Sooooooooo.... I did a little log this evening on the bike. Just wanted to see how bad the battery sag actually is. Here you go:

Click on picture to see it all, its too wide.

Brown=Volts
Green=kmh/speed
Purple=Amps

The graph is so jumpy because I go on fast down a straight, up the hill, turn on the hill, down the hill and so on.

Looks like when I accelerate the batteries sag 20 volts.

Jake

Logger + Cycle analyst Done

So this morning my cycle analyst arrived. High current version. Here are some photos of the insides and hooked up to the logger. Pretty easy install. Logged data well too. I tested with 2 9v batteries in series haha. I also Sealed the logger and cycle analyst for the wellington weather lol.



Plus, how to connect the logger to the computer to charge and the settings.






Yes that it a verti-go in the background :D :D

Jake

Parts Update

I have received so many parcels over the past few weeks it's unbelievable... But totally awesome.
I got my order from sparkfun and have done the Data Logger... I only have to wire it up to the cycle analyst, when that arrives tommorrow. I've used the Logomatic from sparkfun. And 2 of their 3.7v 900mah Lipo Batts in parallel (were on sale for $5 each). With a female usb connector. I think I will move this further in.

I have got loads of other parts... (Also Got an Arduino kit) Connectors for hall sensors motor/controller, connector for cycle analyst/logger, Flasher relay, Polymorph Thermoplastic, 2 Way Alarm, Mirrors and mounts, switch blocks, Tail light, indicators and load resistors, headlight, new front brake and bleeding kit, Koso Digital speedo.


Btw... Was photoshopped in a rush, so mind the rough edges...

Polymorph Is a thermoplastic in which melts at around 60 C. You can put it into boiling water and it will melt, then you can easily mould it or make a mount with it. I will be using it for making mounts and stuff. The alarm will be useful, because I don't want this baby stolen! And all the awesome LED lights, besides the headlight.

Soon arriving will be the eBay volt/amp meter, cycle analyst and 2 Rfid kits.. More info on this stuff when they arrive. I will be using the Rfid reader as ignition, so instead of a key I would just swipe the tag over it and I may have a removable key switch(as in the key can be left in a position and taken out), so I can set it on with the key, but not start or use the bike. Basically so I can use the rfid reader.Once swiped the reader sends out a short pulse so I think I need to wire in a relay to it. We'll see when it's here.
More photos when more stuff arrives.

Jake

3rd Onboard Video: Fully Charged

Another Onboard Video

All Testing Equipment Mounted

Today I mounted all the testing components; control box, controller, 48v lead acid, fuse and voltmeter onto the bike for a couple load runs. When I finished it was dark unluckily, so i attached a mini LED light and off I went. Only a short ride with the lead acids, But I am having problems changing the LVC and configuring the controller. About 20 mins on the non charged, 2008 lead acid 12ah batts.

When Moving all of it over I ran into a couple problems, as before I had the the single connectors for each hall wire. One of them must have lost contact or the wire had come loose because for all of the no load runs with it mounted in the bike, it had the really bad load knocking noise when I gave it throttle. So, My thoughts were " Oh, FU**...!!!" I thought I had connected the hall wires wrong and effed up the hall sensors in the motor!! ARG....... Luckily enough my brother convinced me to take out all the connectors and solder them for a secure connection. And voila, the motor Purrrred again! I then immediatly took it off the axle stands and took it for a little test drive. Acceleration is far better than expected, likewise with the torque. As this is the high speed motor, I expected little torque, especially up the hill where I live. Went up and down the street a couple times. Such fun. The motor was a lot quieter than in the testing and test video.

Here are some pics:










Here's a test video; Onboard:

Motor Testing: No Load

OK, I have now sorted out the motor and tested the controller and everything is working great. I bought the control box from kelly controllers so I could test the motor and controller before mounting it firmly, just in case there was something wrong or if I messed up the hall sensor cables. It took me a while to find it but I looked on the site and found the diagram for the wiring (with colours). Found here: http://www.newkellycontroller.com/product_info.php?cPath=21_62&products_id=135

I used 48v of oldish lead acid batteries I had lying around, which sufficed. Although I connected them to the chargers so I would be able to see it at max voltage. I need to get a speedo hooked up. Will go to a bicycle shop to get s cheap one for tests. I bought a motorcycle speedo, electric and uses a sensor too. This one: http://www.kosonorthamerica.com/fCMSBackend/imgRoot/specs/bb017b00.jpg

Which I probably plan to hook up to one of these to get reading of the batts on the actual normal Petrol tank reading;http://www.evworks.com.au/index.php?product=INS-EVW-FGD

At first I had connected it wrong. Because I wasn't going to use the main contactor I had put the precharge resistor in series on the positive cable. Which meant that it was acting like a voltage resistor. So I kept getting the 0 000 red led sequence, meaning the controller voltage was too low. So i took it out and voila. The motor purrrrrrrrrs.

Here is my setup:











Here is the test video: